OEMs need an exact combination of characteristics for their threaded studs and plugs including wire rope diameter, thread size, thread length and material among others. Lexco Cable specializes in fabricating these assemblies and providing custom solutions when needed.
Below are some frequent questions David Karbin, the Vice President of Lexco Cable, and his team hear from Lexco customers.
Threaded Studs and Plugs Q&A with Lexco Cable’s V.P. David Karbin
What’s the smallest thread size Lexco has made for a customer?
We manufactured a #2-56 thread designed to fit on a 3/64” aircraft cable for a medical application. We make both right hand and left hand thread versions.
- What’s the longest thread length Lexco has made?
We manufactured a stud with 18” of thread length for a bridge application. The thread size was ⅝”-11” and it was engineered to fit on a 3/8” wire rope.
- How does the wire rope’s construction affect the termination?
When a fitting is swaged, the material flows in between the wires. The fewer number of wires the more swage length is needed to achieve the desired pull-off strength. For example, strands such as 1x7 and 1x19 need more swage length than 7x7 or 7x19.
- My threaded plug fails where the cable exits the blind hole. What could be the cause of the stress point?
The stress point may be a result of the cable exiting the blind hole at an angle, or it may be due to cable motion and vibration fatiguing the wires.
- If I need a threaded plug installed onto 1x19 construction, how can I achieve the same pull-off strength that 7x19 yields?
A threaded plug can be custom designed for a 7x19 strand by tapping female thread in the blind hole. The female thread adds a friction grip, which will increase pull-off strength.
- My threaded plug was installed onto 7x7 or 7x19 and pulled-off below the cable break. What can be done?
Extending the swage area will increase the pull-off strength.
- What installation method is used for your threaded studs and plugs?
Most of our end fittings are machine swaged. Please note this means that the force required could not be achieved without a machine and can’t be crimped with a hand tool.
- Can I rent a swaging tool from Lexco?
We have a rental swager designed for cable railing installations.
- Why is my threaded stud cracking when swaged?
The wall thickness of the threaded stud may be too thin. Another possible cause is that the threaded stud is too hard on the Rockwell scale. Annealing the stud can solve the later problem.
- What are your suggestions for controlling cost and lead times when purchasing custom threaded cable ends in low volumes?
Avoiding secondary processes, like zinc plating, will control cost and lead times.
- Does Lexco make other threaded end fittings besides studs and plugs?
Yes! For example, we regularly manufacturer threaded conduit end fittings, which are often called bulkhead fittings.
Lexco Cable is your one-stop shop for wire rope threaded studs and plugs fabricated into assemblies or sold in bulk. If you still have questions, contact us and we’re happy to share our expertise.
Ready to reduce lead times without sacrificing quality?